Rebar Holding and Positioning Apparatus and Method for Reinforcing Concrete Using Rebar

ABSTRACT

A rebar support device for retaining rebar in a position for reinforcing concrete, and method of using the same is claimed. The rebar support device comprises at least one concrete bonding opening dispersed throughout, at least one rebar support chase with bendable retaining gates, and at least one grade stake support hole. The rebar support device is held in a vertical position for receiving rebar by driving a grade stake through the stake support holes, such that the rebar support device is disposed perpendicularly to the rebar it receives. The rebar is then cradled in one or more of the support chases and retained by a bendable retaining gate incorporated into each rebar support device above each support chase.

REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application Ser. No. 60/890,681, entitled “Rebar Holding and Positioning Apparatus and Method for Reinforcing Concrete Using Rebar,” filed on Feb. 20, 2007, which is fully incorporated herein by reference.

FIELD OF THE INVENTION

The present disclosure relates generally to the field of concrete reinforcement. In particular, the present disclosure relates to a rebar holding and positioning apparatus and a method for reinforcing concrete using rebar.

BACKGROUND OF THE INVENTION

Many construction projects require concrete which incorporates reinforcing bar (“rebar”) lattice work for the purpose of adding strength and resisting slab failure should cracks develop. In order to effectively perform this function, the rebar lattice must retain its rectangular lattice shape, and it must be strategically placed—often times suspended near the center of the concrete structure. Current methods for setting the rebar lattice involve placing wire cages, commonly referred to as “rebar chairs,” under the rebar lattice work to elevate the rebar to the desired height, and tying the rebar sections together with wire in order to maintain the rebar lattice when the concrete is poured.

The traditional method is deficient in several ways. First, the wire cages are susceptible to bending and deformation leading to poorly placed rebar and a weaker concrete structure. Second, many rebar chairs are constructed from multiple pieces that may require welding and other preparation or maintenance, causing increased cost and construction time. Furthermore, the traditional method often times requires two or more workers to successfully install the rebar chairs, also causing increased cost and construction time. Finally, the wire tied rebar intersections do not prevent angular deflection, possibly leading to a weaker concrete structure.

The present disclosure addresses each of these deficiencies by providing a one-piece rebar support device which is inexpensive to manufacture and easy to use, and which results in precisely placed rebar and structurally sound reinforced concrete. The present disclosure maintains superior structural integrity due to its one-piece steel construction without joints or welds, and is less likely to be crushed, dislodged, or damaged by the concrete as it is poured. Installation of the present apparatus and method is quick and simple because wire tying is not required. Furthermore, the vertical grade stake which holds the rebar support device in place eliminates the need for wooden grade stakes. Finally, the stackable design of the present disclosure provides for compact storage and handling on the jobsite.

SUMMARY OF THE INVENTION

The present disclosure is directed to an apparatus and method for reinforcing concrete using rebar. For purposes of summarizing the disclosure, certain aspects, advantages, and novel features of the disclosure have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the disclosure. Thus, the disclosure may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

The present disclosure shows the use of multiple one-piece rebar support devices to hold and retain rebar at a desired location within a concrete structure. Each rebar support device contains at least one concrete bonding openings dispersed throughout, at least one rebar support chase with bendable retaining gates, and at least one grade stake support hole. Each rebar support device is held in a vertical position for receiving rebar by driving a grade stake through the stake support holes located at the top and bottom of each piece, such that the rebar support device is disposed perpendicularly to the rebar it receives. The rebar is then cradled in one or more of the support chases and retained by a bendable retaining gate incorporated into each rebar support device above each support chase. Each rebar support device may contain one or more support seams to provide additional support to the structure and to provide additional surface area for bonding of the concrete.

The number and spacing of each rebar support device depends upon the desired rebar lattice work. Once the lattice work has been satisfactorily set in place, the concrete can be poured. The concrete bonding openings allow the concrete to fill voids on either side of each rebar support device used in the lattice work.

In one embodiment, each rebar support device is formed and stamped from sheet metal with a suitable thickness, but in use, the thickness may vary. In other embodiments the rebar support device may be made from other materials and from other processes. Each rebar support device should be of a sufficient strength to support the rebar, yet should be flexible enough to allow the user to bend the retaining gates without the need for additional tools.

These and other embodiments of the present disclosure will also become readily apparent to the those skilled in the art from the following detailed description of the embodiments having reference to the attached figures, the intention not being limited to any particular embodiment or embodiments disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is described with reference to the accompanying drawings.

FIG. 1 shows a perspective view of the rebar support device according to the present disclosure.

FIG. 2 shows an enlarged view of the rebar support device of FIG. 1.

FIG. 3 shows a front perspective view of the rebar support device of FIG. 1.

FIG. 4 shows a perspective view of an alternative embodiment of a rebar support device.

FIG. 5 shows an enlarged view of the rebar support device of FIG. 4.

FIG. 6 shows a front view of an alternative embodiment of a rebar support device.

DETAILED DESCRIPTION

The various embodiments of the present disclosure and their advantages are best understood by referring to FIGS. 1 through 6 of the drawings. The elements of the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the disclosure.

Each construction project will dictate the design of the rebar lattice work needed to reinforce the concrete used in the project. The rebar lattice design must take into account the height and spacing of each piece of rebar, and its placement throughout the concrete structure. Once the design of the lattice work has been determined, the rebar support devices of the present disclosure are strategically placed to retain the rebar in the desired locations, and at the appropriate height and spacing.

FIGS. 1-3 illustrate one embodiment of a rebar support device 105. In this embodiment, the rebar support device 105 comprises a generally planar support plate 190 that is oriented in a generally vertical position when in use. The plate 190 may be formed from sheet metal or any of a number of rigid materials, such as aluminum, steel, plastic, or composite material.

The rebar support device 105 comprises at least one stake support hole 115 that works in conjunction with a grade stake 210 to stabilize the rebar support device 105 and rebar 225. The stake support holes 115 are illustrated in FIG. 3 as tabs 195 on the top edge and the bottom edge of the support plate 190. The stake support holes 115 as illustrated are located along the vertical axis of the plate. In other embodiments, the stake support hole 115 may be positioned elsewhere on the support plate 190.

In the illustrated embodiment, the tabs 195 are formed unitarily with the support plate 190 and are bent generally perpendicularly to the support plate 190 for use. However, in other embodiments the tabs 195 may be formed in other means, or may be bolted or fused to the support plate 190. Each tab 195 comprises a stake support hole 115 through which a grade stake 210 may be driven. The grade stake 210 may be a standard piece of rebar, or may be formed from any suitably rigid material. Each rebar support device 105 is held in place by driving a grade stake 210 through the stake support holes 115 in the tabs 195 located on the top and bottom of the plate 190, and then into the underlying foundation (not shown).

One or more pieces of rebar 225 are then cradled in the rebar support chases 120 effectively retaining the rebar 225 in the desired location. In the illustrated embodiment, the rebar support chases 120 comprise generally U-shaped channels for receiving rebar. The width of the chase is sized to accommodate one piece of rebar 225 and the height is sized to accommodate two pieces of rebar 225. In this manner, the rebar support device 105 may be used to join multiple pieces of rebar. In other embodiments, the rebar support chases may be sized to accommodate different numbers of rebar pieces and orientations. Furthermore, the distance between the rebar support chases 120 and the depth of the rebar support chases 120 are dictated by the design of the rebar lattice work.

Each rebar support chase 120 has a retaining gate 135 at its upper edge. Once the rebar 225 is in place, the user may close the retaining gates 135 to cover the support chase 120 and prevent the rebar 225 from becoming dislodged. In the illustrated embodiment, the gates 135 are unitarily formed with the plate 190 and are bent generally perpendicular to the plate 190 before rebar is introduced into the support chase 120. Then the gates 135 may be closed by bending them back into a generally planar relation to the plate.

Each rebar support device 105 has multiple concrete bonding openings 130 which allow the concrete to maintain continuous contact through and around each rebar support device. The concrete bonding openings 130 may be provided in any number, and may be of any size or shape.

As shown in FIG. 3, the rebar support device 105 may incorporate one or more support seams 140 to provide additional support to the rebar support device and to provide additional surface area for bonding of the concrete. A support seam 140 is formed into the plate 190 as a generally narrow grooved channel.

Furthermore, the rebar support device 105 may include stacking wings 160. Stacking wings 160 may be formed by folding the rightmost and leftmost sides of the plate 190 forward, forming an angle. Stacking wings 160 allow for ease in stacking multiple rebar support devices 105 on top of one another for easy shipment. Stacking wings 160 also allow for increase surface area of the plate 190 for bonding to the concrete.

Alternative shapes and configurations of the rebar support device 105 may be provided. As shown in FIGS. 4 and 5, in an alternative embodiment, a rebar support device 405 is generally T-shaped. Furthermore, instead of retaining multiple pieces of rebar 225 on top of one another, the rebar is positioned side by side in the support chases 415. In another alternative embodiment, as shown in FIG. 6, the rebar support device 605, may include three rebar support chases 120.

This disclosure may be provided in other specific forms and embodiments without departing from the essential characteristics as described herein. The embodiments described above are to be considered in all aspects as illustrative only and not restrictive in any manner.

As described above and shown in the associated drawings, the present disclosure comprises an apparatus and method for reinforcing concrete using rebar. While particular embodiments of the disclosure have been described, it will be understood, however, that the disclosure is not limited thereto, since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is, therefore, contemplated by the appended claims to cover any such modifications that incorporate those features or those improvements that embody the spirit and scope of the present disclosure. 

1. A rebar support device comprising: a plate with at least one stake support hole, and at least one rebar support chase.
 2. The rebar support device of claim 1 further comprising at least one concrete bonding opening.
 3. The rebar support device of claim 1 further comprising at least one support seam.
 4. The rebar support device of claim 1 further comprising at least one retaining gate.
 5. The rebar support device of claim 1 further comprising at least one stacking wing.
 6. A method comprising the steps of: driving a grade stake through a stake support hole of a rebar support device; and positioning a first rebar within a first rebar support chase of said rebar device.
 7. The method of claim 6 further comprising the step of positioning a second rebar within said first rebar support chase.
 8. The method of claim 6 further comprising the step of closing a retaining gate adjacent to said first rebar support chase, wherein said first rebar is immovably positioned within said first rebar support chase.
 9. A rebar support device comprising a plate with at least one rebar support chase, and at least one retaining gate.
 10. The rebar support device of claim 9 further comprising at least one stake support hole.
 11. The rebar support device of claim 10 wherein said stake support hole is located along the vertical axis of said plate.
 12. The rebar support device of claim 11 wherein said retaining gate is located adjacent to said rebar support chase, such that closing said retaining gate fixedly retains at least one rebar within said rebar support chase.
 13. The rebar support device of claim 12 further comprising at least one concrete bonding opening.
 14. The rebar support device of claim 11 further comprising at least one support seam.
 15. The rebar support device of claim 11 further comprising at least one stacking wing. 